Apparatus and methods for feeding sheets of material from stacks with one side in vertical registration

ABSTRACT

Apparatus and methods for feeding sheets of material from stacks with one side in vertical registration wherein the method comprises stacking the sheets flat on a generally horizontal support with the bottom of the lowermost sheet in contact with lateral propulsion means, exerting a vacuum on the lowermost sheet from beneath sufficient to significantly increase the force of contact between the lowermost sheet and the said lateral propulsion means and preferably sufficient to deflect the lowermost sheet around the propulsion means to a limited degree, simultaneously propelling the lowermost sheet from beneath by the propulsion means laterally against a side guide and thereafter propelling the lowermost sheet forwardly while in contact with the side guide. The apparatus comprises a generally horizontal support having at least one vacuum chamber open at the top of the support, the support and chamber conveniently being defined by a plurality of spaced apart, generally upstanding flat bars, means for generating a vacuum communicating with the said chamber, power driven lateral propulsion means in proximity to the chamber, said propulsion means projecting above the top of the support and engageable with the bottom of the lowermost sheet of the stack. The said propulsion means conveniently being a power driven rotatable roller positioned within the chamber between spaced apart bars, a side guide engageable with the side edge of the lowermost sheet in the direction of lateral propulsion, and means for propelling the lowermost sheet forwardly while in contact with the side guide, said means being conveniently a reciprocating feeder bar.

United States Patent Hawthorne [451 July 18, 1972 William C. Hawthorne,218 Phelps Road, Ridgewood, NJ. 07450 22 Filed: March 26, 1971 21Appl.No.: 128,480

[72] inventor:

[52] U.S. Cl. ..27l/29, 271/44 A [51 Int. Cl. ..B65h 1/06, B65h 3/08[58] Field oISearch ..27l/29, 32, 44 R, 44 A,52,

[5 6] References Cited UNITED STATES PATENTS 1,201,361 10/1916Schwerdtle ..27l/29 Primary ExaminerEdward A. Sroka Attorney-Popper,Bain, Bobis & Gilfillan [57) ABSTRACT Apparatus and methods for feedingsheets of material from stacks with one side in vertical registrationwherein the method comprises stacking the sheets flat on a generallyhorizontal support with the bottom of the lowermost sheet in contactwith lateral propulsion means, exerting a vacuum on the lowermost sheetfrom beneath sufficient to significantly increase the force of contactbetween the lowermost sheet and the said lateral propulsion means andpreferably sufficient to deflect the lowermost sheet around thepropulsion means to a limited degree, simultaneously propelling thelowermost sheet from beneath by the propulsion means laterally against aside guide and thereafter propelling the lowermost sheet forwardly whilein contact with the side guide.

The apparatus comprises a generally horizontal support having at leastone vacuum chamber open at the top of the support, the support andchamber conveniently being defined by a plurality of spaced apart,generally upstanding flat bars, means for generating a vacuumcommunicating with the said chamber, power driven lateral propulsionmeans in proximity to the chamber, said propulsion means projectingabove the top of the support and engageable with the bottom of thelowermost sheet of the stack. The said propulsion means convenientlybeing a power driven rotatable roller positioned within the chamberbetween spaced apart bars, a side guide engageable with the side edge ofthe lowermost sheet in the direction of lateral propulsion, and meansfor propelling the lowermost sheet forwardly while in contact with theside guide, said means being conveniently a reciprocating feeder bar.

8 Claim, 5 Drawing figures Patented July 18, 1972 3,677,537

3 Shee cs-Sheet 1 IIVVENTOR M. T. HAWTHORNE POPPER, BAl/V, 808/5 8GlLF/LLA/V ATTORNEYS Patented July 18, 1972 3,677,537

3 Sheets-Sheet F1 FIG. 2

Patented July 18, 1972 3 Sheets-SheetAPPARATUSANDME'I'HODSPDRFEHJINGSHEEISOF MATERIAL FROM STACKS WITH ONESIDE [N VERTICAL REGISTRATION BACKGROUND OF THE INVENTION In thecorrugated cardboard arts, it is common practice to feed sheets ofcardboard into machines which stamp and diecut them for folding intocanons or other shapes. Such machines are well known in the art.

It is necessary to feed sheets of uncut cardboard into such blankingmachines. It is common practice to stack sheets of cardboard one abovethe other in a generally horizontal plane, the stack resting upon afeeder table. A feeder bar is engageable with the lowermost sheet ofcardboard propelling it forwardly along the top of the feeder table andinto the nip of a pair of rollers in the blanking machine.

In order to stamp, die-cut, print or otherwise manipulate the sheet ofcardboard precisely, it is necessary to size or dimension the cardboardsheet precisely feeding it into the machine with a high degree ofconstant registration.

Unfortunately, existing machinery for the manufacture of sheet cardboardcannot dimension each sheet precisely. Thus, means must be provided inthe blanking machine for trimming the cardboard to a precise size.

Existing feeder tables, however, do not provide means for bringing atleast one side edge of each sheet of cardboard in registration with eachof the other sheets as it feeds into the machine. Rather, the stack ofcardboard rests upon an ordinary feeder table having means merely topropel the lowermost sheet into the nip of the lead rollers. Side guideson the stack must be spaced apart a distance at least as wide as thewidest sheet of the stack. As a result, each sheet of cardboard must betrimmed in the blanking machine on both lateral side edges to dimensionthe cardboard precisely and, from that point, bring it into preciseregistration with dies, folding devices and the like. This results inthe loss of the trimmed portions on both sides of the sheet.

lt is among the objects and advantages of the present invention toprovide methods and apparatus for feeding sheets of material such ascardboard into a blanking machine wherein one lateral side edge of eachsheet is in registration with every other sheet as it feeds into theblanking machine thereby requiring trimming on only one side edge asdistinguished from existing machinery and feeder tables which requiretrimming on both side edges.

The method of feeding disclosed and claimed therein includes means forpropelling the lowermost sheet of the stack laterally against a sideguide. Preferably, the lateral propulsion means are at least one andpreferably a plurality of rollers seated within recesses or chambers inthe feeder table and projecting slightly above the top plane of thetable, being engageable to the bottom of the lowermost sheet. While suchpropulsion means would tend to drive the lowermost sheet laterallyagainst the side guide, this will not occur with the speed and certaintyrequired by the timing of the reciprocating feeder bar propelling thesheet forwardly into the nip of the rollers. The feeder must operatevery rapidly which leaves an extremely short period of time for thelowermost sheet to adjust against the side guide before the feeder barforces it to the rollers. Thus, means must be provided to insure ahighfrictional contact between the lateral propulsion means and thebottom of the lowermost sheet.

It is among the further objects and advantages of the present inventionto provide a vacuum in proximity to the lateral propulsion means whichdraws the lowermost sheet downwardly into firm contact with thepropulsion means. In addition, the vacuum tends to slightly deform theIOWemlOSt sheet around the lateral propulsion means or rollers insuringa near positive contact and extremely rapid movement laterally to theside guide.

SUMMARY OF THE INVENTION A method for feeding sheets of material fromthe bottom of a stack with one side of the sheets in verticalregistration when feeding forwardly comprising stacking the sheets flaton a generally horizontal support with the bottom of the lowermost sheetin contact with lateral propulsion means, exerting a vacuum on thelowemiost sheet from beneath sufficiently to significantly increase theforce of contact between the lowermost sheet and the said lateralpropulsion means, simultaneously propelling the lowermost sheet frombeneath laterally against a side guide, and thereafter propelling thelowermost sheet forwardly while in contact with the side guide.

A pneumatic, trim-saving feeder for feeding sheets of material from thebottom of a stack comprising a generally horizontal support having atleast one chamber open at the top of the support, means for generating avacuum in the said chamber, lateral propulsion means in proximity to thechamber, said propulsion means projecting above the top of the supportand engageable with the bottom of the lowermost sheet in the stack, aside guide engageable with the side edge of the lowermost sheet in thedirection of lateral propulsion, and means for propelling the lowermostsheet forwardly while in contact with the side guide.

PREFERRED EMBODIMENT OF THE INVENTION The objects and advantagesaforesaid as well as other objects and advantages may be achieved by themethods and apparatus claimed herein, a preferred embodiment of theapparatus being illustrated in the drawings in which:

FIG. I is a view in perspective of a pneumatic, trim-saving feeder;

FIG. 2 is an end elevational view of the feeder taken along line 2-2 inFIG. 1 looking in the direction of the arrows and illustrating theeffect of vacuum on the lowermost sheet in contact with power drivenrollers;

FIG. 3 is a side elevational, cross-sectional view of the feeder takenalong line 3-3 in FIG. I looking in the direction of the arrows;

FIG. 4 is an enlarged, partially broken away view in perspective of anadjustable side guide illustrated in FIG. 1; FIG. 5 is an enlarged,partially broken away view in perspective of an alternate form ofadjustable side guide.

Referring now to the drawings in detail the feeder comprises a support 1l fabricated from a plurality of generally upstanding, flat rectangularbars. The support consists of a front wall 12, a pair of side walls 13and 14 and a rear wall IS. The support is also provided with a pluralityof spaced apart spacing bars [6, 16 extending between the front wall 12and rear wall 15. The spacing bars 16 define a plurality of chambers 17open atthetopofthe support 11.

Each of the chambers 17 is provided with an opening 18 communicatingwith a vacuum manifold 19. The vacuum manifold 19 is connected to asuitable source of vacuum.

Alternate chambers are provided with friction rollers 20, 20 mounted onshafls 21 extending between the front wall 12 and the rear wall 15 ofthe support 11. Each of the shafis 21 extends through the rear wall 15and is provided with a terminal bevel gear 22.

A main drive shaft 23 is mounted behind the rear wall 15 of the support11 extending through ends of the spacing bars 16,16. The drive shaft 23is provided with bevel gears 24, 24 which are engaged with therespective bevel gears 22 on shafts 21 carrying the rollers 20.

One of the shafts 21 extends through a closure wall 25 parallel to rearwall 24 and is provided with a sheave 26. Sheave 26 is coupled throughbelt 27 to a drive pulley 28 on a motor 29. Thus, motor 29 drives eachof the rollers 20 in the same direction.

A pair of reciprocating bed slides 30, 31 are mounted on opposite sidesof the support 11. The bed slides are coupled to and carry a feeder bar32. The reciprocating bed slides 30 and 31 and the feeder bar 32 areconventional and need no further detailing. In addition, a plurality offront feed gates 33, 33 are positioned above and spaced away from thefront wall 12 of the support 1 l. A pair of nip rollers 34, 34 arelocated in front of the front wall 12 of the support H. The front feedgata 33, 33 and nip rollers 34 are conventional and need no furtherdetailing. In addition, a side wall guide 35 is provided over thesupport 11 on one side thereof which is conventional and which lendssupport to the stack of sheet mounted on the sup port I 1.

On the side of the support 11 opposite the guide 35, a second,adjustable guide 36 is located. The entire guide 36 is slidably mountedon a support bar 37 by means of a suitable collar 38 and thumb screw 39.Thus, the entire guide 36 is laterally movable transverse to the support1 l.

The guide 36 is comprised of a pair of parallel, spaced apart plates 40,40 defining a central slot 41. Spacing blocks 42, 42 are secured to theplates 40, 40 at opposing ends.

Each of the plates 40, 40 are provided with slots 43, 43 in the topedges thereof in opposition to each other.

An insert 44 is slidably mounted in the slot 41 and suspended by atransverse bar 45 in the top thereof extending through the opposed slots43, 43. In order to stabilize the insert 44 against rocking on the shaft45, a stabilizing block 46 is mounted on the top of the insert 44 andextends across the top of the plates 40, 40.

The bottom of the insert 44 is provided with a nylon block 47. Theinsert 44 and nylon block 47 extend beneath the bottom edge 48 of theplates 40, 40.

The combined effect of the rollers 20, 20 and the vacuum in chambers 17on the lowermost sheet of cardboard 49 is best illustrated in FIG. 2.The lowermost sheet 49 is drawn downwardly against the top edges 50, 50of the spacing bars 16. However, the topmost edge of each of the rollers20, 20 projects above the top edges 50 of the spacing bars 16. As aconsequence, the lowermost sheet of cardboard 49 is drawn downwardlyover the topmost edge of the rollers 20 deforming the cardboard slightlyat that point. The vacuum not only increases the force of contactbetween the roller 20 and the cardboard 49 but makes that contact at anangle which enhances the frictional engagement therebetween. In thisregard, the surface of the roller 20 may be provided with a rubber orother frictional sheet 51. As a consequence of the forceful and intimatecontact between the lowermost sheet 49 and the rollers 20, the lowermostsheet 49 is rapidly propelled laterally until its side edge engages thenylon block 47 on the bottom of the insert 44 in the adjustable guide36. This then defines the farthest extent of lateral movement of thelowermost sheet 49. The engagement between the sheet 49 and the rollers20 is so efficient from the standpoint of propulsion, the sheet 49 israpidly propelled the usual very short distance between its edge and thenylon block 47 certainly in good time before the reciprocating feederbar 32 engages the rear edge of the sheet 49 to propel it forwardly intothe nip rollers 34, 34.

The sheet 52 above the lowermost sheet 49 is gravity fed downwardly tothe support 1 l as the lowermost sheet 49 is fed forwardly into theblanking machine. Sheet 52 then becomes the lowermost sheet and is movedlaterally to engagement with the nylon blocks 47 on the bottom of theinserts 44 of the adjustable guide 36.

It should be noted that the guide 36 is adjustable for varying widths ofthe cardboard sheets from front to back. The farthest extent ofreciprocation of the feeder bar 32 is adjustable to accommodate fordiffering widths from front to back. In order to accommodate for alonger stroke of the feeder bar 32, the insert 44 may be moved forwardlyor rearwardly from slot to slot 43, 43 so that the feeder bar 32 willnot strike the bottom of insert 44. It should also be noted that morethan one insert 44 may be employed if necessary to insure a long enoughguide surface.

An alternate form of side guide is illustrated in FIG. 5. The side guideconsists of an upper rail 52 and a lower rail 53 parallel to the upperrail 52. The upper rail 52 is rigidly attached to a mounting member 54which is in turn secured to the principal apparatus. The lower rail 53is pivotally mounted to the supporting member 54 at one end. A sideguide wall 55 is rigidly mounted to the lower rail 53 extending upwardlyto one side of the upper rail 52. A friction hinge $6 is secured betweenthe upper and lower rails 52 and 53.

The lower rail is also provided with a cam surface 57 at its endopposite the support 54.

In operation, the guide wall 55 which may be moved rearwardly orforwardly on the bottom rail 53 provides an abutment surface for thefeed stock. In the event that the reciprocating feeder bar 32 encroachesupon the lower rail 53, it will engage the cam surface 57 pivoting thelower rail 53 upwardly folding the hinge 56 and preventing damage to thefeeder bar 32.

The foregoing description is merely intended to illustrate an embodimentof the invention. The component parts have been shown and described.They each may have substitutes which may perform a substantially similarfunction; such substitutes may be known as proper substitutes for thesaid components and may have actually been known or invented before thepresent invention.

I claim:

1. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising,

a. a generally horizontal support having at least one vacuum chamberopen at the top of the support,

b. means for generating a vacuum in the vacuum chamber,

c. lateral propulsion means in the support, at least a portion of saidlateral propulsion means projecting above the top of the support andengageable with the bottom of the lowermost sheet of the stack,

d. a side guide engageable with the side edge of the lowermost sheet inthe direction of lateral propulsion, and

e. means for propelling the lowen-nost sheet forwardly while in contactwith the side guide.

2. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising,

a. the structure in accordance with Claim 1 in which b. at least aportion of at least one vacuum chamber lies on opposite sides of thelateral propulsion means.

3. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising,

a. the structure in accordance with Claim 2 in which,

b. the lateral propulsion means are at least one driven roller mountedon the feeder, a portion of the top of the roller extending above thetop of the support.

4. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising,

a. the structure in accordance with claim 3 in which b. the said sideguide is adjustably movable both along the axis of lateral propulsionand along the axis of forward propulsion.

5. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising,

a. the structure in accordance with claim 4 in which b. the supportconsists of a plurality of spaced apart, generally upstanding barsextending generally parallel to the axis of forward propulsion of thesheets. the said bars defining open-taped chambers therebetween,

c. at least one of said rollers being mounted in one of the chambers,and

d. vacuum generating means connected to at least one chamber on oppositesides of the roller.

6. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising,

a. the structure in accordance with Claim 5 and b. vacuum generatingmeans connected to at least one of the chambers having a roller mountedtherein.

7. A method for feeding sheets of material from the bottom of a stackwith one side of the sheets in vertical registration when feedingforwardly comprising,

IOI045 (H64 6 a. stacking the sheets generally horizontally on agenerally in contact with the side guide.

horizontal support with the bottom of the lowermost 8. A method forfeeding sheets of material from the bottom sheet in contact with lateralpropulsion means, of a stack with one side of the sheets in verticalregistration c. exerting a vacuum on the lowermost sheet from beneathwhen feeding forwardly comprisi g.

sufficiently to significantly increase the force of contact 5 the methodin mdame with Claim 7 in which,

between th l we sheet d h id l mpromb. the lowermost sheet is deformeddownwardly from a Sion means, horizontal plane on opposite sides of thelateral propuld. simultaneously propelling the lowermost sheet frommeans at Partially in respome the Vacuum beneath laterally against aside guide, and thereone. thereafter propelling the lowermost sheetforwardly while 10 It r

1. A pneumatic, trim-saving feeder for feeding sheets of material fromthe bottom of a stack comprising, a. a generally horizontal supporthaving at least one vacuum chamber open at the top of the support, b.means for generating a vacuum in the vacuum chamber, c. lateralpropulsion means in the support, at least a portion of said lateralpropulsion means projecting above the top of the support and engageablewith the bottom of the lowermost sheet of the stack, d. a side guideengageable with the side edge of the lowermost sheet in the direction oflateral propulsion, and e. means for propelling the lowermost sheetforwardly while in contact with the side guide.
 2. A pneumatic,trim-saving feeder for fEeding sheets of material from the bottom of astack comprising, a. the structure in accordance with Claim 1 in whichb. at least a portion of at least one vacuum chamber lies on oppositesides of the lateral propulsion means.
 3. A pneumatic, trim-savingfeeder for feeding sheets of material from the bottom of a stackcomprising, a. the structure in accordance with Claim 2 in which, b. thelateral propulsion means are at least one driven roller mounted on thefeeder, a portion of the top of the roller extending above the top ofthe support.
 4. A pneumatic, trim-saving feeder for feeding sheets ofmaterial from the bottom of a stack comprising, a. the structure inaccordance with claim 3 in which b. the said side guide is adjustablymovable both along the axis of lateral propulsion and along the axis offorward propulsion.
 5. A pneumatic, trim-saving feeder for feedingsheets of material from the bottom of a stack comprising, a. thestructure in accordance with claim 4 in which b. the support consists ofa plurality of spaced apart, generally upstanding bars extendinggenerally parallel to the axis of forward propulsion of the sheets, thesaid bars defining open-taped chambers therebetween, c. at least one ofsaid rollers being mounted in one of the chambers, and d. vacuumgenerating means connected to at least one chamber on opposite sides ofthe roller.
 6. A pneumatic, trim-saving feeder for feeding sheets ofmaterial from the bottom of a stack comprising, a. the structure inaccordance with Claim 5 and b. vacuum generating means connected to atleast one of the chambers having a roller mounted therein.
 7. A methodfor feeding sheets of material from the bottom of a stack with one sideof the sheets in vertical registration when feeding forwardlycomprising, a. stacking the sheets generally horizontally on a generallyhorizontal support with the bottom of the lowermost sheet in contactwith lateral propulsion means, c. exerting a vacuum on the lowermostsheet from beneath sufficiently to significantly increase the force ofcontact between the lowermost sheet and the said lateral propulsionmeans, d. simultaneously propelling the lowermost sheet from beneathlaterally against a side guide, and e. thereafter propelling thelowermost sheet forwardly while in contact with the side guide.
 8. Amethod for feeding sheets of material from the bottom of a stack withone side of the sheets in vertical registration when feeding forwardlycomprising, a. the method in accordance with claim 7 in which, b. thelowermost sheet is deformed downwardly from a horizontal plane onopposite sides of the lateral propulsion means at least partially inresponse to the vacuum exerted thereon.